Adjustable firmness mattress

ABSTRACT

A mattress system. The mattress system including a foam mattress having a plurality of stacked layers, wherein each of the stacked layers has a top surface and a bottom surface thereby defining a plurality of interstitial pockets and one or more rigid plates configured to be inserted into the one or more plurality of interstitial pockets, thereby enabling the mattress system be selectively optimized to provide a desired structural support and firmness for a user&#39;s body type and weight.

RELATED APPLICATION INFORMATION

This application claims the benefit of U.S. Provisional Application 62/317,541, filed Apr. 2, 2016, which is hereby incorporated by reference.

TECHNICAL FIELD

The present disclosure relates generally to bed mattresses. More particularly, the present disclosure relates to foam bed mattresses having a plurality of slots into which a stiffening member can be inserted for the purpose of adjusting firmness.

BACKGROUND

Sleep plays an important role in a person's overall health and enjoyment of life. The quality and quantity of sleep affects the body's ability to function normally and the ability to reach peak performance. Physiologically, sleep affects brain activity, heart rate, blood flow to the brain, sexual arousal, and body temperature. Sleep deprivation shows a strong correlation to obesity, diabetes, stroke, depression, and hypertension. Restful sleep is dependent upon the level of comfort while lying prone. Concentration of pressure on certain parts of the body and/or poor skeletal alignment are been linked to restless sleep. Sleeping on a mattress or other support surface that does not properly support and conform to the shape of the body or to the spine's natural curves can significantly contribute to restlessness or inability to sleep.

Traditionally sleep systems incorporate a mattress consisting of an outer layer of fabric and padding, surrounded by a series of spring coils. The fabric is stretched tightly across the padding to hold them in place, which in many eases creates a surface that is too hard. The mattress is usually supported by a flexible box spring, thereby enabling the mattress to compress where needed. However, the stiffness of the box springs can cause It to push back against the mattress in areas of greatest compression.

More recently, foam mattresses have been developed to provide adequate support without the use of spring coils. Current foam technology can be categorized according to load bearing capacity by time and temperature variables. A standard measure of Indentation Load Deflection (ILD) or Indentation Force Deflection (IFD) is a scaled range measurement of the load bearing capacity and deformation properties of flexible foam, measured as a force required to compress the sample to a fixed percentage of the sample initial height pursuant to ASTM D3574. Rates of recovery and thermal response rates of foam samples are also measured.

Although conventional foam mattresses provide the advantage of shape conformity and thermal responsiveness, structural support is sacrificed, particularly in areas of highest load concentrations. Although changing the stiffness of a foam mattress can alleviate this problem to some degree, the optimal stiffness should be different depending on body type and weight. U.S. Bedding manufacturers tend to ignore body types and weight, and market sleep systems constructed under an inaccurate assumption that 95% of the population has the same body type.

Accordingly, what is needed in the industry is an improved mattress that can be selectively optimized to provide the desired structural support for an individual's body type and weight. Moreover, what is needed in the industry is a bedding system in which the firmness can be adjusted repeatedly, and without a significant increase In manufacturing cost.

SUMMARY OF THE DISCLOSURE

Embodiments of the present disclosure meet the need of the industry for an improved mattress that can be repeatedly and selectively optimized to provide the desired structural support for an individual's body type and weight, without a significant increase in manufacturing costs that would normally be associated with such an individualized sleep system.

One embodiment of the present disclosure provides a mattress system configured to be selectively optimized to provide a desired structural support and firmness for a user's body type, and weight. The mattress system can include a foam mattress and one or more rigid plates. The foam mattress can have a plurality of stacked layers. Each of the stacked layers can have a top surface and a bottom surface, thereby defining a plurality of interstitial pockets between the individual stacked layers. The one or more rigid plates can be configured to be inserted into the one or more plurality of interstitial pockets.

In one embodiment, the foam mattress can have a width of approximately 39 inches and a length of approximately 74 inches. In one embodiment, the foam mattress can have a width of approximately 54 inches and a length, of approximately 74 inches. In one embodiment, the foam mattress can have a width of approximately 60 inches and a length of approximately 80 inches. In one embodiment, the foam mattress can have a width of approximately 76 inches and a length of approximately 80 inches. In one embodiment, the plurality of stacked layers can be fused together at one of the head end of the mattress, the foot end of the mattress, the centerline of the mattress, or a combination thereof.

In one embodiment, the one or more rigid plates can he constructed of plastic. In one embodiment, the one or more rigid plates can be constructed of wood. In one embodiment, the one or more rigid plates can have a length of between 65 and 75 inches. In one embodiment, the one or more rigid plates can have a length of between 12 and 36 inches. In one embodiment, the one or more rigid plates can have a length of between 6 and 12 inches. In one embodiment, the one or more rigid plates can have a width of between 30 and 39 inches. In one embodiment, the one or more rigid plates can include a handle. In one embodiment, the one or more rigid plates can include a hinge section. In one embodiment, the intersection is a living hinge.

In one embodiment, a first rigid plate can be inserted into a first interstitial pocket, thereby establishing a first portion of the mattress system having a first firmness, and a second rigid plate can be inserted into a second interstitial pocket, thereby establishing a second portion of the mattress system having a second firmness. In one embodiment, a portion of the first rigid plate and the second rigid plate can overlap, thereby establishing a third portion of the mattress having a third firmness.

In one embodiment, the mattress system can further include a third rigid plate, which can be inserted into the first interstitial pocket, thereby establishing a third portion of the mattress system with a firmness substantially equal to the first firmness. In one embodiment, a portion of the first rigid plate can overlap with a portion of the second rigid plate, thereby establishing a fourth portion of the mattress having a fourth firmness, and a portion of the second rigid plate can overlap with a portion of the third rigid plate, thereby establishing a fifth portion of the mattress having a fifth firmness.

One embodiment of the present disclosure provides a mattress system configured to be selectively optimized to provide a desired structural support and firmness for a user's body type and weight. The mattress system can include a foam mattress and a rigid plate. The foam mattress can have a plurality of stacked layers, wherein each of the stacked layers has a top surface and a bottom surface, thereby defining a plurality of interstitial pockets between the individual stacked layers. The rigid plate can be configured to be inserted into one of the plurality of interstitial pockets, wherein the rigid plate includes at least one hinge section configured to enable the rigid plate to bend. In one embodiment, the hinge section can enable the rigid plate to fold over itself, thereby doubling its thickness over a first portion. In one embodiment, the hinge section can enable the rigid plate to fold over itself twice, thereby tripling its thickness over a first portion.

One embodiment of the present disclosure provides a method of optimizing the firmness of a mattress system to provide a desired structural support for a user's body type and weight, such that one or more rigid plates is inserted and positioned within one or more of a plurality of interstitial pockets within a foam mattress, wherein the interstitial pockets are defined between a plurality of stacked layers, wherein each of the stacked layers has a top surface and a bottom surface.

The summary above is not intended to describe each illustrated embodiment or every implementation of the present disclosure. The figures and the detailed description that follow more particularly exemplify these embodiments.

BRIEF DESCRIPTION Of THE DRAWINGS

The disclosure can be more completely understood in consideration of the following detailed description of various embodiments of the disclosure, in connection with the accompanying drawings, in which;

FIG. 1 is a perspective view depicting a mattress system in accordance with an embodiment of the disclosure.

FIG. 2 is a top view depicting a mattress system in accordance with an embodiment of the disclosure, wherein the plurality of stacked layers are fused together at the head, foot and center of the mattress.

FIG. 3 is a perspective view depicting a mattress system with a rigid plate having a plurality of hinge sections in accordance with an embodiment of the disclosure.

FIG. 4 is a perspective view depicting a mattress system having two rigid plates in accordance with an embodiment of the disclosure, wherein the rigid plates are inserted into an interstitial pocket such that a gap is defined between the two rigid plates.

FIG. 5 is a perspective view depicting a mattress system having two rigid plates in accordance with an embodiment of the disclosure, wherein the first rigid plate is inserted into a first interstitial pocket and the second rigid plate is inserted into a second interstitial pocket, such that the first and second rigid plates overlap.

FIG. 5 is a perspective view depicting a mattress system having three rigid plates in accordance with an embodiment of the disclosure, wherein the first rigid plate is inserted into a first interstitial pocket, the second rigid plate is inserted into a second interstitial pocket and the third plate is inserted into a third interstitial pocket, such that the first and second rigid plates overlap and second and third rigid plates overlap.

While embodiments of the disclosure are amenable to various modifications and alternative forms, specifies thereof are shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, a mattress system 100 is depicted in accordance with an embodiment of the disclosure. Mattress, system 100 can include a mattress 102 and one or more rigid plates 104. In one embodiment, the mattress 102 can be constructed of foam and can conform to standard mattress dimensions. For example, the mattress 102 can measure approximately: 39 inches wide by 74 inches long (twin), 39 inches wide by 80 inches long (twin extra long), 54 inches wide by 74 inches long (full), 60 inches wide by 80 inches long (queen), 76 inches wide by 80 inches long (king), and 72 inches wide by 84 inches long (California king).

The mattress 102 can include a plurality of stacked layers 106A-F. In one embodiment, there are six stacked layers 106. In other embodiments, there may be any number of stacked layers 106. Each of the plurality of stacked layers 106 can include atop surface 108 and a bottom surface 110. A plurality of interstitial pockets 112 can be defined by the respective top surfaces 108 and bottom surfaces 110 of adjacent stacked layers 106. In one embodiment, the plurality of stacked layers 106 are fused together at least at one of the head of the bed 114, the foot of the bed 116, the lateral center of the bed 118, or a combination thereof. For example, in one embodiment the mattress 102 is constructed as a unitary foam member, and the plurality of interstitial pockets 112 are cut into the side of the mattress 102, thereby forming the plurality of stacked layers 106.

In one embodiment, the mattress 102 can include a covering 120 configured to protect the plurality of stacked foam layers 106. In some embodiments, the covering 120 can include a seam (not depicted) along one edge configured to selectively enable access to the plurality of interstitial pockets 112. The seam can be scalable, for example by a series of buttons or snaps, a zipper, hook and loop fasteners, or other conventional fabric-fasteners.

The rigid plate 104 can be configured to be inserted into one of the interstitial pockets 112. The rigid plate 104 can be constructed of a rigid material, such as wood, plastic, hard foam rubber, or other conventional material with an element of rigidity. The rigid plate 104 can include one or more handles 122, configured to enable a user to more easily grip and manipulate the rigid plate 104.

In some embodiments, the rigid plate 104 is shaped and sized to fit within an interstitial pocket 112. In one embodiment, the rigid plate 104 has a shape to approximate a standard mattress size, or a half standard mattress size, with a reduction in size to accommodate where portions of the stacked layers 106 are fused together at least at one of the head of the bed 114 the foot of the bed 116, the center of the bed 118, or a combination thereof. For example, in one embodiment, the rigid plate 104 has a width of between 30-39 inches and a length of between 65-75 inches.

Referring to FIG. 3, a rigid plate 104 having a plurality of hinge sections 128 is depicted in accordance with an embodiment of the disclosure. In one embodiment, the hinge sections 128 can be living hinges. For example, in one embodiment, rigid plate 124 can be constructed of a unitary sheet having a plurality of thicknesses, wherein portions of greater thickness represent the rigid members 126 and portions of lesser thickness represent the living hinge sections 128. In another embodiment, the plurality of rigid members 126 are contained in a fabric housing, wherein the fabric housing between the rigid members 126 represents the hinge sections 128.

Hinge sections 128 can enable a user to more easily move the rigid plate, as the hinge sections can flex, particularly when going around corners within the confines of a user's residence. Hinge sections 128 can also enable a user to told portions of the rigid plate 124 over on itself, thereby doubling or tripling the thickness of the rigid plate 124 over certain portions of overlap. Such portions of overlap may be desirable in cases where greater support and additional mattress firmness are desired. For example, a user may prefer additional support under their head and/or feet, and therefore may fold a portion of rigid plate 124 over on itself in order to double its thickness prior to insertion into the interstitial pocket 112. In another example, a user may prefer additional support under their lower back, and may fold a portion of the rigid plate 124 over on itself twice in order to triple its thickness prior to insertion into the interstitial pocket 112.

Referring to FIGS. 4 and 5, a mattress system 100 including two rigid plates 104 is depicted in accordance with an embodiment of the disclosure. In some embodiments, the length of the rigid plate 104 can be substantially less than the length of the interstitial pocket 112. for example, in some embodiments, the length of the rigid plate 304 can be between 6-12 inches, between 12-36 inches, or any length that fits within interstitial pocket 112.

In some instances, a user may desire greater support under certain portions of their body, and lesser support under other portions of their body. In such instances, two or more rigid plates 104 can be inserted into one or more of the interstitial pockets 112 with a gap 130 defined therebetween. In some instances, the two-or more rigid plates 104 can be inserted into the same interstitial pocket 112. In other embodiments, particularly where differing levels of support are desired, the two or more rigid plates 104 can be inserted into different interstitial pockets 112.

In some instances, a user may desire differing layers of support across the mattress 102, with the greatest support desired across a midsection of the mattress 102. In such instances, two or more rigid plates 104 can be inserted into the one or more interstitial pockets 112, wherein the two or more rigid plates 104 have a first overlapping portion 132.

Referring to FIG. 6, a mattress system 100 including three rigid plates 104 is depicted in accordance with an embodiment of the disclosure. In some instances, a user may desire differing layers of support across the mattress 102 with several areas of greater support across a midsection of the mattress 102. In such instances three or more rigid plates 104 can be inserted into the one or more interstitial pockets, wherein the three or more rigid plates have a first overlapping portion 132 and a second overlapping portion 134.

In operation, a user can selectively customize their mattress system 100 to provide the desired structural support and firmness for their body type and weight by positioning one or more rigid plates 104 within the interstitial pockets 112 defined in mattress 102. For example, in one embodiment, a user may desire greater support uniformly across the entire mattress 102. In such an instance, the user can insert one or more rigid plates 104 in a single interstitial pocket. Placement of the rigid plate 104 in the interstitial pocket 112 closest to the top/sleeping surface of the mattress 102 will provide maximum support, while placement of the rigid plate 104 in the interstitial pocket 112 farthest from the top/sleeping surface of the mattress 102 will provide minimal support.

In instances where differing levels of support are desired across the mattress 102, two or more rigid plates 104 can be positioned in different interstitial pockets 112. For example, a first rigid plate 104A can be placed in a first interstitial pocket 112, and a second rigid plate 104B can be placed in a second interstitial pocket 112. Where no support is desired in a midsection of the mattress 102, a gap 130 can be left between the first rigid plate 104 and the second rigid plate 104. Where greater support is desired in a midsection of the mattress 102, the first rigid plate 104A and the second rigid plate 104B can be positioned such that they establish an overlapping portion 132.

Where a more complex level of support is desired, a third rigid plate 104C can be inserted into an interstitial pocket 112. In some instances, a gap 130 can be left between the third rigid plate 104C and the first and/or second rigid plates 104A/B. In other instances, a second overlapping portion 134 can be established by overlapping the third rigid plate 104C with either or both of the first and second rigid plates 104A/B.

It should be understood that the individual steps used in the methods of the present teachings may be performed in any order and/or simultaneously, as long as the teaching remains operable. Furthermore, it should be understood that the apparatus and methods of the present teachings can include any number, or all, of the described embodiments, as long as the teaching remains operable.

Persons of ordinary skill in the relevant arts will recognize that embodiments may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted. Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended. Furthermore, it is intended also to include features of a claim in any other independent claim even if this claim is not directly made dependent to the independent claim.

Moreover, reference in the specification to “one embodiment,” “an embodiment,” or “some embodiments” means that a particular feature, structure, or characteristic, described in connection with the embodiment, is included in at least one embodiment of the teaching. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

Any Incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein. 

What is claimed is:
 1. A mattress system configured to be selectively optimized to provide a desired structural support and firmness for a user's body type and weight, comprising: a foam mattress having a plurality of stacked layers, wherein each of the stacked layers has a top surface and a bottom surface, thereby defining a plurality of interstitial pockets between the individual stacked layers; and one or more rigid plates configured to be inserted into one or more of the plurality of interstitial pockets.
 2. The mattress system of claim 1, wherein the one or more rigid plates are constructed of plastic.
 3. The mattress system of claim 1, wherein the one or more rigid plates are constructed of wood.
 4. The mattress system of claim 1, wherein the one or more rigid plates are constructed of hard foam rubber.
 5. The mattress system of claim 1, wherein the one or more rigid plates has a length of between 65 and 75 inches.
 6. The mattress system of claim 1, wherein the one or more rigid plates has a length of between 12 and 36 inches.
 7. The mattress system of claim 1, wherein the one or more rigid plates has a length of between 6 and 12 inches.
 8. The mattress system of claim 1, wherein the one or more rigid plates has a width of between 30 and 39 inches.
 9. The mattress system of claim 1, wherein the one or more rigid plates includes a handle.
 10. The mattress system of claim 1, wherein the one or more rigid plates includes a hinge section.
 11. The mattress system of claim 10, wherein the intersection is a living hinge.
 12. The mattress system of claim 1, wherein the plurality of stacked layers are fused together at one of the bead end of the mattress, the foot end of the mattress, the centerline of the mattress, or a combination thereof.
 13. The mattress system of claim 1, wherein a first rigid plate is inserted into a first interstitial pocket, thereby establishing the first portion of the mattress system having a first firmness, and a second rigid plate is inserted into a second interstitial pocket, thereby establishing a second portion of the mattress system having a second firmness.
 14. The mattress system of claim 13, wherein a portion of the first rigid plate and the second rigid plate overlap, thereby establishing a third portion of the mattress having a third firmness.
 15. The mattress system of claim 13, further including a third rigid plate inserted into the first interstitial pocket, thereby establishing a third portion of the mattress system with a firmness substantially equal to the first firmness.
 16. The mattress system of claim 15, wherein a portion of the first rigid plate overlaps a portion of the second rigid plate, thereby establishing a fourth portion of the mattress having a fourth firmness, and a portion of the second rigid plate overlaps a portion of the third rigid plate, thereby establishing a fifth portion of the mattress having a fifth firmness.
 17. A mattress system configured to be selectively optimized to provide a desired structural support and firmness for a user's body type and weight, comprising; a foam mattress having plurality of stacked layers, wherein each of the stacked layers has a top surface and a bottom surface, thereby defining a plurality of interstitial pockets between the individual stacked layers; and a rigid plate configured to be inserted into one of the plurality of interstitial pockets, wherein the rigid plate includes at least one hinge section configured to enable the rigid plate to bend.
 18. The mattress system of claim 17, wherein the hinge section enables the rigid plate to fold over itself, thereby doubling its thickness over a first portion.
 19. The mattress system of claim 17, wherein the hinge section enables the rigid plate to fold over itself twice, thereby tripling its thickness over a first portion.
 20. A method of optimizing the firmness of a mattress system to provide a desired structural support for a user's body type and weight, comprising: positioning one or more rigid plates into one or more of a plurality of interstitial pockets within a foam mattress, wherein the interstitial pockets are defined between a plurality of stacked layers, wherein each of the stacked layers has a top surface and a bottom surface. 